Surgical instrument having a plastic surface

ES 2 396 594 T3

DESCRIPTION

Surgical instrument that has a plastic surface

Background

Technical field

The present description refers to a surgical instrument and a disposable loading unit that include a plastic surface thereon. More particularly, the present disclosure relates to a surgical instrument that includes a plastic surface on at least one of a closure apparatus and a contact surface of a tool assembly.

Background

Surgical devices in which tissue is first grasped or clamped between an opposing jaw structure and then attached by surgical fasteners are well known in the art. In some instruments, a blade is provided to cut the tissue that has been joined by the fasteners. The fasteners are normally in the form of surgical staples but two-piece polymeric fasteners can also be used.

Instruments for this purpose may include two elongated elements that are used respectively to capture or grasp tissue. Typically, one of the elements carries a staple cartridge that houses a plurality of staples arranged in at least two lateral rows while the other element has an anvil that defines a surface to form the staple legs as the staples are driven from the staple cartridge. In some instruments, the closure of the two elongated elements, or tool assembly, is affected by the actuation of a movable handle that moves a drive bar having a closure apparatus thereon to a contact surface of an assembly. of tool, thus bringing the elements of the tool set together. There may be a large frictional force between the closure apparatus and the contact surface of the tool assembly, thus possibly requiring that a relatively large amount of force be applied to the movable handle.

EP 1 7 02 568 discloses a tool assembly for a surgical stapler. The tool assembly has an anvil, cartridge assembly, collar, and dynamic clamp. The dynamic clamp includes a pin that engages with the anvil. The preamble of appended claim 1 is based on its description.

Summary

In accordance with the present invention there is provided a surgical instrument (500) comprising: a handle portion (510); a body portion (512) extending distally from the handle portion (510); and a tool assembly (17) supported at a distal end of the body portion (512), the tool assembly (17) including a cartridge assembly (18), and an anvil assembly (20) supported adjacent the assembly. Cartridge (18), the anvil assembly (20) being movable relative to the cartridge assembly (18) from an open position to a closed position, The tool assembly (17) further including a closure element (800 ') having an upper flange portion (802') and a lower flange portion (804 ') interconnected by a vertical bar portion (806'), the closure member (800 ') being movable relative to the tool assembly (17) to maintain a desired tissue gap adjacent the closure member (800'), characterized in that at least one of the upper rim portion (802 ') and the lower rim portion (804') includes an external surface (807 '), an internal surface (808') and a hole (822 '), extending the hole between the outer surface (807 ') and the inner surface (808'), wherein a material (812 ') having a low coefficient of friction is located within the hole (822') and on at least a portion of the inner surface (808 ') of at least one of the portion (802') upper flange and the lower flange portion (804 ').

In one embodiment, the moldable material is plastic.

In one embodiment, the rim part includes an upper rim part and a lower rim part that are interconnected by the vertical bar part.

In one embodiment, the hole is provided through both the upper rim portion and the lower rim portion, and the moldable material is injected through each of the holes in the upper and lower rim portions.

In one embodiment, the inner surface of each of the upper and lower rim portions defines at least one recess and the moldable material is injected into the recesses through the holes.

Description of the drawings

Various embodiments of the surgical instrument disclosed herein are disclosed herein with reference to the drawings, in which:

Figure 1 is a side perspective view from the distal end of one embodiment of the presently disclosed surgical instrument with an articulated tool assembly;

Figure 1A is a side perspective view from the proximal end of a disposable loading unit (DLU) of the surgical instrument shown in Figure 1 that includes the tool assembly;

Figure 2 is a side perspective view of the distal end of the mounting assembly and tool assembly, with parts separated, of the DLU of the surgical instrument shown in Figure 1;

Figure 3 is a side perspective view of the mounting assembly and proximal body portion of the DLU shown in Figure 1A with parts separated;

Figure 3A is a side perspective view of a coupling element of the surgical instrument shown in Figure 1;

Figure 3B is a side perspective view of a top mounting portion of the DLU mounting assembly of the surgical instrument shown in Figure 1;

Figure 3C is a side perspective view of a lower mounting portion of the DLU mounting assembly of the surgical instrument shown in Figure 1;

Figure 3D is a top side perspective view of the proximal body portion, mounting assembly and tool assembly of the DLU of the surgical instrument with the tool assembly in its non-articulated position;

Figure 3E is a top side perspective view of the proximal body portion, mounting assembly, and tool assembly shown in Figure 3D with the tool assembly in an articulated position;

Figure 3F is a bottom side perspective view of the proximal body portion, mounting assembly and tool assembly of the DLU of the surgical instrument with the tool assembly in its non-articulated position;

Figure 3G is a side perspective view from below of the proximal body portion, mounting assembly, and tool assembly shown in Figure 3F with the tool assembly in an articulated position;

Figure 4 is a side cross-sectional view of the DLU tool assembly shown in Figure 1A;

Figure 5 is a top perspective view of the locking element actuator of the proximal body part locking mechanism shown in Figure 3;

Figure 6 is a bottom perspective view of a locking member of the locking mechanism shown in Figure 3;

Figure 7 is a top view of the proximal end of the DLU proximal body portion shown in Figure 1A with the locking mechanism in its locked position;

Figure 8 is a cross-sectional view taken along section lines 8-8 of Figure 7;

Figure 9 is a top view of the proximal end of the DLU proximal body portion shown in Figure 1A with the locking mechanism in its unlocked position;

Figure 10 is a cross-sectional view taken along section lines 10-10 of Figure 9;

Figure 11 is a side perspective view of the DLU and surgical instrument shown in Figure 1 prior to attachment of the DLU to the surgical instrument;

Figure 12 is a top view of the proximal end of the DLU and the distal end of the surgical instrument shown in Figure 11 prior to attachment to the distal end of the surgical instrument;

Figure 13 is a top view of the proximal end of the DLU shown in Figure 11 as the DLU is linearly advanced into the distal end of the surgical instrument;

Figure 14 is a top view of the proximal end of the DLU and the distal end of the surgical instrument shown in Figure 12 after the DLU has been linearly advanced but prior to locking the DLU to the surgical instrument;

Figure 15 is a top view of the proximal end of the DLU and the distal end of the surgical instrument shown in Figure 13 after the DLU has been linearly advanced and rotatably locked over the surgical instrument;

Figure 16 is a perspective view of a locking assembly for use with a surgical instrument according to one embodiment of the present disclosure;

Figure 17 is a perspective view of various components of the lock assembly of Figure 16;

Figure 18 is an enlarged perspective view of a portion of the locking assembly of Figures 16 and 17 illustrated with the articulated tool assembly in a non-articulated position;

Figure 19 is an enlarged perspective view of a portion of the locking assembly of Figures 16-18 and including a connecting piece;

Figure 20 is an enlarged perspective view of a portion of the locking assembly of Figures 16-19 illustrated with the articulated tool assembly in an articulated position;

Figure 21 is an enlarged perspective view of another locking assembly for use with a surgical instrument in accordance with one embodiment of the present disclosure;

Figure 22 is an enlarged bottom perspective view of the lock assembly of Figure 21;

Fig. 23 is a perspective view of a drive bar having a plurality of layers and a closure apparatus according to an embodiment of the present disclosure;

Figure 24 is a perspective view of the drive bar and closure apparatus of Figure 23 with parts separated;

Figure 25 is a cross-sectional view of a portion of the drive bar and closure apparatus of Figures 23 and 24;

Fig. 26 is a cross-sectional view of a drive bar and a closure apparatus according to an embodiment of the present disclosure;

Figure 27 is a cross-sectional view of the actuator bar and closure apparatus of Figure 26;

Figure 27a is a perspective view of a closure member according to an embodiment of the present invention;

Figure 27b is a cross-sectional view of the closure member shown in Figure 27a taken along section lines 27b-27b of Figure 27a;

Figure 27c is a perspective view of the closure element shown in Figure 27a prior to attachment of the insert;

Figure 27d is a cross-sectional view of the closure member taken along section lines 27d27d of Figure 27c;

Figure 28 is a perspective view of a tool assembly according to one embodiment of the present disclosure; ^Y Figure 29 is an assembly view of the tool assembly of Figure 28.

Detailed description of realizations

Embodiments of the surgical instrument and DLU disclosed herein will now be described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the various views.

Referring to FIG. 1, surgical instrument 500 includes a handle portion 510, a body portion 512, and a disposable loading unit ("DLU") 16. Handle portion 510 includes a stationary handle 514 and a movable handle. or trigger 516. Movable handle 516 is movable relative to stationary handle 514 to advance a control rod 520 protruding from the distal end of body portion 512. The handle portion 510 and the body portion 51 2 may be constructed in the manner disclosed in US Patent No. 6,330,965. Alternatively, other surgical instruments with DL U 16 can be used to perform endoscopic surgical procedures.

Referring to Figures 1 and 1A, in summary, the DLU 16 includes a tool assembly 17, a proximal body portion 200, and a mounting assembly 202. Body portion 200 has a proximal end adapted to releasably engage the distal end of a surgical instrument 500 (FIG. 11) in a manner that will be discussed in detail below. The mounting assembly 202 is pivotally attached to a distal end of the body portion 2 00 and is securely attached to a proximal end of the tool assembly 17. The pivotal movement of the mounting assembly 202 with respect to an axis perpendicular to a longitudinal axis of the body portion 200 affects the articulation of the tool assembly 17 between a non-articulated position in which the long axis

The end of the tool assembly 17 is aligned with the longitudinal axis of the body part 200 and an articulated position in which the longitudinal axis of the tool assembly 17 is disposed at an angle with respect to the longitudinal axis of the part. 200 body.

Referring to Figures 2-4, the tool assembly 17 includes a cartridge assembly 18 and an anvil assembly 20. Anvil assembly 20 includes an anvil portion 28 having a plurality of staple deformation recesses 30 (FIG. 4) and a cover plate 32 attached to an upper surface of anvil portion 28. Cover plate 32 and anvil portion 28 define a cavity 34 (FIG. 4) therebetween that is dimensioned to receive a distal end of a drive assembly 212 (FIG. 3). Cover plate 32 encloses the distal end of drive assembly 212 to prevent tissue pinching during actuation of DLU 16. A longitudinal slot 38 extends through the anvil portion 28 to facilitate passage of a retaining lip 40 of the actuator assembly 212. A cam surface 42 formed on the yu n portion 28 which is positioned to engage with a pair of cam members 40a supported on the retaining rim 40 of the drive assembly 212 to effect the approximation of the anvil and cartridge assemblies. A pair of pivot elements 44 are formed. A pair of stabilization elements 50 engage with a respective shoulder 52 formed on a carrier 48 to prevent the anvil portion 28 from sliding axially relative to the staple cartridge 54 as the cam surface 42 is pivoted with relative to the pivot elements 44.

Cartridge assembly 18 includes a carrier 48 defining an elongated support channel 56 that is sized and configured to receive staple cartridge 54. Corresponding tabs 58 and slots 60 formed along the staple cartridge 54 and elongated support channel 56, respectively, function to retain the staple cartridge or 54 at a fixed location within the support channel 56. A pair of support struts 62 formed on the staple cartridge 54 are positioned to rest on side walls of the holder 48 to further stabilize the staple cartridge 54 within the support channel 56. Carrier 48 has slots 46 for receiving pivot elements 44 of anvil portion 28 and allowing anvil portion 28 to move between spaced and approximate positions.

Staple cartridge 54 includes retention slots 64 (FIG. 2) for receiving a plurality of staples or fasteners 66 and pushers 68. A plurality of laterally spaced longitudinal slots 70 extend through staple cartridge 54 to accommodate wedges 72 vertical camming of an actuation harrow 74 (Figure 2). A central longitudinal slot 76 extends along substantially the length of the staple cartridge 54 to facilitate the passage of a knife blade 78 (FIG. 4). During operation of surgical stapler 10, actuation assembly 212 abuts actuation harrow 74 and pushes actuation harrow 74 through longitudinal slots 70 of staple cartridge 54 to advance cam wedges 72 into a position. sequential contact with pushers 68. Pushers 68 translate vertically along cam wedges 72 into fastener retention slots 64 and drive fastener elements 66 from retention grooves 64 into staple deformation cavities 30 (FIG. 4 ) of the anvil assembly 20.

Referring to FIG. 3, the mounting assembly 235 includes an upper mounting portion 236 and a lower mounting portion 238. A centrally located pivot element 284 extends from the upper mounting portion 236 through a respective opening 246a formed in a first coupling element 246. The lower mounting portion 238 includes a bore 239 to receive the pivot member 284 (see FIG. 3F). Pivot element 284 extends through bore 239 and opening 247a of a second coupling element 247. Each of the coupling elements 246, 247 includes a proximal interlocking portion 246b, 247b configured to be received in notches 290 formed in the distal end of an internal housing that is formed from upper and lower housing halves 250 and 252. Coupling elements 246, 247 retain mounting assembly 235 and upper and lower housing halves 250 and 252 in a longitudinally fixed position relative to each other while allowing pivotal movement of mounting assembly 235 relative to them. .

Referring to Figures 3A-3C, each coupling element 246, 247 includes a cantilevered spring arm 246c having a distal end 246d positioned to engage mounting assembly 235. More specifically, the upper mounting portion 236 includes an upper surface 236a that includes a recess 236b dimensioned to receive the distal end 246d of the spring arm 246c of a respective coupling element 246. The lower mounting portion 238 includes a bottom surface 238a having a pair of raised surfaces 238b defining a recess 238c that is dimensioned to receive the spring arm 247c of a respective coupling element 247. Alternatively, at least one recess may be formed in the proximal end of the tool assembly 17.

As illustrated in Figures 3D-3G, when the distal end of spring arms 246c, 247c of coupling elements 246, 247 are located in recesses 236b and 238c of upper and lower mounting portions 236 and 238, respectively, spring arms 246c, 247c retain mounting assembly 235 in a non-articulated position. The spring arms 246c, 247c will retain the mounting assembly 235 in its unarticulated position until a predetermined force is applied sufficient to bias the spring arms 246c from the recesses 236b and 238c to effect the articulation of the mounting assembly 235 and the tool set 17. When the predetermined force is applied to mounting assembly 235 and tool assembly 17, spring arms 246c, 247c will be spring-loaded or deflected outwardly from recesses 236b and 238c, as shown in Figs. Figures 3E and 3G, to allow pivotal movement of the mounting assembly 235 (and thus the tool assembly 17) relative to the distal end of the proximal portion 200 of the DLU 16 body.

ES 2 396 594 T3

As discussed above, spring arms 246c and recesses 236b and 238c hold tool assembly 17 in its non-hinged position until a predetermined force has been applied to mounting assembly 235 to disengage arms 246c, 247c. spring from recesses 236b and 238c of mounting assembly 235. It is envisaged that the spring arms / recesses can be incorporated into any hinged surgical device including staplers, clamps (see Figure 3H), powered sealing devices, eg RF sealing devices, etc. Also, although two spring arms / recesses are shown, a single spring arm may be provided. Furthermore, the articulated tool assembly need not be part of a DLU but rather can be supported directly on the distal end of a surgical instrument. For example, the mounting assembly may be removably or removably attached to the tool assembly and attached directly to the distal end of a surgical instrument.

The upper housing half 250 and the lower housing half 252 are contained within an outer jacket 251 of the body portion 200 (FIG. 3). Body portion 200 includes a cutout 251a sized to receive a shoulder 250a formed in the upper housing half 25 0. The location of the boss 250a within the cutout 251a prevents axial and rotational movement of the upper and lower housing halves 250 and 252 within the outer sleeve 251 of the body portion 200. In one embodiment, the shoulder 250a has a substantially rectangular configuration that has a greater axial dimension than the lateral dimension. The larger axial dimension provides an increased surface area to prevent rotation of upper and lower housing halves 250 and 252 within sleeve 251. A proximal portion 250b of shoulder 250a is sloped. Sloped proximal portion 250b allows sleeve 251 to slide over shoulder 250a as upper and lower housing halves 250 and 252 are positioned within sleeve 2 51. It is foreseen that the resa lte 2 50a can assume other configurations, for example, circular, square, triangular, etc., and still achieve its intended function. In addition, the shoulder 250a may be relocated anywhere along the upper housing half 250 or, alternatively, located in the lower housing half 252 or partially in each housing half 250 and 252.

The proximal end or insertion tip 193 of the upper housing half 250 includes latching buttons 254 for releasably engaging the distal end of a surgical instrument in a bayonet-like mode (see Figures 1A and 7). Housing halves 250 and 252 define a channel 400 for slidably receiving axial drive assembly 212 therein. An articulated connecting piece 256 is dimensioned to slidably locate within a slot 402 formed between the upper and lower housing halves 250 and 252. A pair of H-block assemblies 255 are positioned adjacent the distal end of the housing portion 200 and adjacent the distal end of the axial drive assembly 212 to prevent deformation and outward buckling of the drive assembly 212 during articulation and firing of the surgical stapling apparatus 10. Each H-block assembly 255 includes a flexible body 255a that includes a proximal end securely attached to body portion 200 and a distal end securely attached to mounting assembly 235 (FIG. 3).

A retainer 288 is supported in the engagement section 270 of the axial drive assembly 212. Retainer 288 includes a pair of fingers 288a that are releasably positioned within grooves or recesses 252a formed in lower housing half 252. In operation, when the SULU 16 is attached to a surgical instrument and the axial actuation assembly 212 is actuated by applying a predetermined force to an actuation element 516 of the surgical instrument 500 (FIG. 11), the actuation assembly 212 Axial gear is advanced distally to move actuator assembly 212 and retainer 288 distally. As retention element 288 is advanced distally, fingers 288 are forced from recesses 252a to provide an audible and tactile indication that the surgical instrument has been actuated. The retainer 288 is designed to prevent inadvertent partial actuation of the DLU 16, such as during shipping, by holding the axial actuation assembly 212 in a fixed position within the DLU 16 until a predetermined axial force has been applied to the axial drive assembly 212.

The axial drive assembly 212 includes an elongated drive rod 266 that includes a distal working head 268 and a proximal engagement section 270. In one embodiment, drive bar 266 is constructed from multiple stacked sheets of material. Latch section 270 includes a pair of resilient latch fingers 270a and 270b which when assembled engage a pair of corresponding detent grooves formed in actuator 272. Actuator 272 includes a proximal hole 274 configured to receive the distal end of a control rod 520 (FIG. 11) of a surgical instrument when the proximal end of DLU 16 engages with the body portion 512 of a surgical instrument 500. .

Referring also to Figures 5-10, the DLU 16 further includes a locking mechanism that includes a locking member 300 and a locking member actuator 302. The locking element 300 (FIG. 6) is rotatably supported within an axial or longitudinal slot 310 (FIG. 7) formed in a proximal portion of the upper housing half 250 of the DLU 16 body portion 200. The locking element 300 can be moved from a first position (Figures 7 and 8), in which the locking element 300 maintains the actuation assembly 212 in a pre-firing position, to a second position (Figures 9 and 10 ), wherein the drive assembly 212 is free to move axially.

As illustrated in FIG. 6, the locking element 300 includes a semi-cylindrical body 312 that is slidably positioned within the transverse groove 310 formed in the upper housing half 250 of the body portion 200. Body 312 includes a radially inwardly extending cam member 314 and finger 316 that extends

ES 2 396 594 T3 extends radially inward. Finger 316 is dimensioned to slidably receive within a notch or slot 270c (FIG. 3) formed in drive assembly 212. Engagement of finger 316 in notch 270c of actuator assembly 212 prevents actuator assembly 212 from moving linearly within body portion 200 and thus prevents actuation of DLU 16.

Referring to Figures 3, 5 and 7, a locking element actuator 302 is slidably positioned within an axial slot 320 (Figure 7) formed in the upper housing half 250 of the body portion 200 of the DLU 16. Actuator 302 includes a proximal stop element 322, a distal spring guide 324, and a central cam slot 326. The axial slot 320 cuts the transverse slot 310 so that the cam member 314 of the locking member 300 is slidably positioned within the eva slot 326 of the locking member actuator 302. A displacement element or spring 328 (FIG. 7) is positioned around the spring guide 324 between a distal surface 330 of the actuator 302 and a wall 332 (FIG. 7) that defines the distal end of the axial slot 320. Spring 328 urges actuator 302 to its retracted position within axial slot 320. In its retracted position, the abutment member 322 is located at and extends radially outward from the proximal end of the DLU 1 6 adjacent the insertion tip 193 of the proximal body portion 200 and the cam slot 326 is located to locate cam member 314 such that finger 316 of locking member 300 is located within bar 270c of actuator assembly 212.

Figures 11-15 illustrate DLU 16 and surgical instrument 500 prior to and during attachment of DLU 16 to surgical instrument 500. Prior to attachment of DLU 16 to surgical instrument 500, spring 328 urges actuator 302 to its retracted position to move locking element 300 to its locked position as discussed above. When the insertion tip 193 of the DLU 16 is linearly inserted into the open end 522 (FIG. 11) of the body portion 512 (FIG. 13) of a surgical instrument 500, the buttons 254 move linearly through of the grooves (not shown) formed in the open end 522 of the body portion 512. As buttons 254 pass through the slots, the proximal end 322a of stop member 322, which is angularly offset from buttons 254, abuts a wall 276c that defines the slots for receiving buttons 254. As As the DLU 16 further moves into the body portion 512, the locking member actuator 302 moves from its retracted position to its advanced position in the direction indicated by arrow "T" in FIG. 14. As actuator 302 moves to its forward position, locking element 300 engages in the direction indicated by arrow "U" in FIG. 14 from its locked position (FIG. 8) engaged with drive assembly 212 to its unlocked position (FIG. 10) to move the dock 316 from notch 270c. The locking mechanism that includes the locking element 3 00 and the locking element actuator 302 prevents accidental or inadvertent advancement or manipulation of the DLU 16 drive element such as during loading of the DLU 16 on a surgical instrument 500.

When DLU 16 has been moved linearly relative to instrument 500 to a position where a proximal surface 530 of body portion 200 abuts internal surface 276c of body portion 512 (FIG. 15), the D LU 16 can be rotated relative to the body portion 512 in a bayonet-like action to position the buttons 254 within the openings 536 of the body portion 512 to lock the DLU 16 in the body portion 512. It is envisioned that other types of couplings in addition to bayonet couplings may be used to connect the DLU 16 to the instrument 500, for example, snap fit or spring retention couplings, friction fit couplings, interlocks, threaded couplings , etc.

In one embodiment of the present disclosure illustrated in Figures 16-20, a locking assembly 600 for use with the surgical instrument 500 and a disposable loading unit 16 are illustrated (see Figure 1, for example). In the illustrated embodiments, the lock assembly 600 includes a housing 602, a pusher 604, a rod 606, a carriage 608, at least one spring 610, a cam finger 612, a pivot plate 614 having grooves 616, and a part 618 of connection. The locking assembly 60 0 generally assists the tool assembly 17 (see FIG. 1, for example) in maintaining its position during firing of the surgical instrument 500.

Referring to Figures 16 and 17, a portion of the lock assembly 600 is at least partially contained within a housing 602. Figure 16 illustrates the lock assembly 600 disposed relative to the housing 602, while Figure 17 i polishes isolated locking assembly 600 from housing 602. In the illustrated embodiment of FIG. 17, pusher 604 is shown with rod 606 extending distally therefrom. Carriage 608 extends distally from rod 606 and has a sliding relationship therewith, thus allowing carriage 608 to move axially relative to rod 606. Spring 610 or pair of springs (not explicitly shown in this embodiment) distally displaces carriage 608 from rod 606.

Referring now to Figures 18-20, cam finger 612 and pivot plate 614 are illustrated. Cam finger 612 extends distally from carriage 608 and pivot plate 614 may be disposed on mounting assembly 235 (see FIG. 3), for example. It is envisaged that the pivot plate 614 may be arranged in or incorporated with a portion of the tool assembly 17. A plurality of slots 616 (five slots 616 are illustrated) are provided in the pivot plate 614 and are dimensioned to accept at least a portion of the cam finger 612 therein. With different amounts of articulation of the tool assembly 17 (not including substantial articulation) with respect to the body portion 512 (see Figure 1, for example), the cam finger 612 is roughly aligned with an individual slot 616 of the pivot plate 614. Figures 18 and 19 illustrate cam finger 612 substantially

ES 2 396 594 T3 aligned with a central groove 616a (which cannot be seen in FIG. 19) and FIG. 20 illustrates the cam finger 612 substantially aligned with a lateral groove 616b.

Connecting piece 618, illustrated in Figures 17 and 19, is mechanically engaged with pivot plate 614 and cam finger 612. (In FIG. 18, the connecting piece has been removed.) The connecting piece 618 is illustrated as having an opening 620 and a slot 622 (FIG. 19). Aperture 620 has a pivotal relationship with a shoulder 624 on pivot plate 614 and slot 622 is slidably engaged with cam finger 612. This relationship allows for articulation of pivot plate 614 relative to body portion 512 and longitudinal translation of carriage 608 relative to pivot plate 614.

In operation, with at least partial actuation of the movable handle 516 (see Figure 1, for example), the pusher 604 is forced distally, for example, through a control rod 520 (see Figure 11, for example) , thus causing distal translation of cam finger 612 at least partially into a slot 616 of pivot plate 614. Actuation of movable handle 516 to approximate cartridge assembly 18 and anvil assembly 20 (see FIG. 1A, for example) is intended to also function to translate cam finger 612 distally. In such an embodiment, when the articulated tool assembly 17 is in place and is fixed in tissue, further articulation cannot be achieved (without releasing the movable handle 516, for example). Thus, the locking assembly 600 helps to hold the articulated tool assembly 17 in position relative to the body portion 512, prior to placing the staples in tissue, for example.

As discussed above, spring 610 distally displaces carriage 608 from rod 606. This displacement provided by spring 610 helps ensure that cam finger 612 does not accidentally or prematurely dislodge from slot 616 in plate 614. pivot, which can result in a significant amount of "play" in between. Additionally, the distal displacement provided by spring 61 0 helps to eliminate tolerances and / or manufacturing clearances that are present between carriage 6 08 and pivot plate 614. It is also envisioned that at least a portion of the cam finger 612 and / or slot 616 may be wedge-shaped to help reduce any inadvertent movement therebetween. In such an embodiment, a distal portion of cam finger 612 and slot 616 would be narrower than a corresponding proximal portion.

In one embodiment of the present disclosure illustrated in Figures 21 and 22, a locking assembly 700 for use with the surgical instrument 500 and a disposable loading unit 16 is illustrated (see Figure 1, for example). In the illustrated embodiment, the lock assembly 700 includes an adapter 702, a pusher 704, a pivot 706, a displacement element (eg, a pair of springs 708), and a connecting piece 710. Lock assembly 700 generally helps to maintain tool assembly 17 in a predetermined position.

Referring to FIG. 21, adapter 702 of locking assembly 700 is generally housed within body portion 512 (see FIG. 1, for example) of surgical instrument 500 or within disposable loading unit 16. In the illustrated embodiment, pusher 704 is located distally to a pair of springs 708. Pusher 704 is distally displaced by means of pair of springs 708 toward pivot 706 of articulated tool assembly 17. A distal portion of pusher 704 includes a pusher engaging surface 712 (FIG. 22) that is shaped and dimensioned to engage a pivot engaging surface 714 (FIG. 22) disposed adjacent the proximal portion of pivot 706. The connecting piece 710 is illustrated acting in conjunction mechanically with a portion of the pusher 704 and pivotally connected to a portion of the pivot 706, thereby allowing the articulated tool assembly 17 to move between its first position and its second position with with respect to the body part 512. More specifically, connecting piece 710 includes an opening 711 that fits over a boss 707 of pivot 706, thus allowing pivot movement therebetween. Furthermore, the connecting piece 710 is slidably engaged with a portion of the adapter 702, thus allowing longitudinal movement therebetween.

Referring now to Figure 22, the pusher engagement surface 712 is substantially flat along a large portion of its length in this embodiment. Correspondingly, the pivot engaging surface 714 is also flat along a large portion of its length in the illustrated embodiment. Thus, distal movement of pusher 704 toward pivot 706 (in the direction of arrow A) by spring pair 708 helps to maintain articulated tool assembly 17 in its first, non-articulated position, while the displacement force assists the articulated tool assembly 17 to resist pivoting. Although two springs 708 are illustrated, more or fewer springs 708 may be provided.

To pivot the articulated tool 17 from its first, non-articulated position, the distal displacement force of the pair of springs 708 must be overcome. Such pivoting action moves the pusher 704 proximally (in the direction of arrow B). Against the displacement of the spring pair 708. The pusher engagement surface 714 is also envisioned to include retaining elements (not explicitly shown in this embodiment) to help stabilize the articulated jaw member 17 in selected articulated positions.

With continued reference to Figure 22, pivot 706 includes a base 716 thereon. As shown in FIG. 22, base 716 overlaps at least a portion of pusher 704 when pusher engaging surface 712 is in contact with pivot engaging surface 714. Base 716 is located and configured

ES 2 396 594 T3 to help prevent tissue from being pinched between pusher 704 and pivot 706 when articulated tool assembly 17 is rotated and / or articulated.

In one embodiment of the present disclosure illustrated in Figures 23-25, a multi-layer drive rod 750 is illustrated having a plurality of layers 750a-750e and may be included in a disposable loading unit 16 (see Figure 1, for example). Also illustrated is a closure apparatus 760, such as an I-bar. The closure apparatus 760 includes a horizontal portion 762 that can be advanced into the cam surface 42 (or other contact surface) to approximate the tool assembly tool assembly 17, as described in detail above with reference to figure 2.

Referring to FIG. 24, the multilayer drive bar 750 is illustrated having five layers 750a 750e. It is envisioned and within the scope of the present disclosure that fewer or more layers may be used to form the multilayer drive bar 750. It is also envisioned that the multilayer drive bar 750 may replace the drive bar 266 in other embodiments of this disclosure. The use of the multilayer drive bar 750 can provide increased strength and flexibility during use, specifically, for example, while the tool assembly 17 is in an articulated position.

A plurality of cutouts 770 are illustrated in Figures 23-25 ​​extending through each layer of the multilayer drive bar 750. Although the figures show between five and ten cutouts per layer of the multilayer drive bar 750, the exact number of cutouts 770 may be less than five, between five and ten, or greater than ten. Additionally, cutouts 770 from adjacent layers of drive bar 750 may or may not align with each other. The use of cutouts 770 reduces the cross-sectional dimensions of the drive bar 750 and allows adjustment of the bending force. Although rectangular cutouts 770 are illustrated, the use of cutouts 770 having other regular or non-regular shapes is also contemplated.

The attachment of each layer 750a - 750e of the multilayer drive bar 750 and the attachment of the closure apparatus 760 are illustrated in Figure 25. In the illustrated embodiment, an outer layer (750a or 750e of Figure 24) is attached to the closure apparatus 760 at two locations (each location being indicated by reference numeral 780 in FIG. 25), by means of a pair of spot welds, for example. Each outer layer 750a, 750e is also envisioned to include an opening 776 that fits over a shoulder 778 protruding from the closure apparatus 760. Each outer layer 750a, 750e is also attached to an adjacent layer (eg, 750b or 750d) at two locations (each location being indicated by reference numeral 781 in Figure 25), possibly by means of a pair of weld welds. points. Additionally, each inner layer (e.g. 750b, 750c, and 750d) is bonded to an adjacent inner layer (e.g. 750b is bonded to 750c; 750c is bonded to 750b and 750d; and 750d is bonded to 750c) at two locations. , by means of spot welding, for example. Although spot welding is disclosed as a method of joining, other methods of joining each layer to each other and the outer layers to the closure apparatus are envisaged and are within the scope of the present disclosure. The illustrated embodiments show attachment points 780 of the inner layers adjacent to the closure apparatus 760, although it is envisioned and within the scope of the present disclosure that the attachment points 780 are disposed at other locations on the actuation bar 750. Additionally, it is envisaged that at least one layer of the drive bar 750 is made of a metal, such as stainless steel. The parts of the drive bar 750 and / or the closure apparatus 760 may also be made of or at least partially covered with a plastic material, as described below. In addition, the closure apparatus 790 may include a cutting surface 766 (FIG. 23) therein for cutting tissue.

In one embodiment of the present disclosure illustrated in Figures 26 and 27, a closure apparatus 800 and a drive bar portion 802 are shown. The closure apparatus and / or a contact surface (eg, cam surface 42) of tool assembly 17 (see Figure 2, for example) may include a plastic surface or plastic coating. In this embodiment, the closure apparatus 800 is illustrated as having a pair of caps 804 that at least partially cover the horizontal portions 806 of the closure apparatus 800. Caps 804 can be made of plastic in this embodiment. Such plastic surfaces provided on the closure apparatus 800 and / or the contact surface of the tool assembly 17 generally reduce the amount of friction therebetween relative to two metal surfaces. That is, a plastic-to-metal or plastic-to-plastic interaction can create less friction than the interaction between a pair of metal surfaces. This reduced amount of friction can correspond to a reduced firing force.

It is envisaged that a portion of the closure apparatus 800, such as a pair of caps 804, is made of plastic, overmoulded with plastic, or includes a plastic coating. Additionally, a contact surface of the tool assembly 17, or at least a part thereof, may also be made of plastic, be overmolded with plastic, or include a plastic coating.

In one embodiment of the disclosure, the closure apparatus 800 may include an I-shaped cross section, such as illustrated in Figures 26 and 27. Additionally, the closure apparatus 800 and actuator bar 802 may be part of a disposable loading unit 16 and / or part of a hinged surgical instrument 500. In addition, drive bar 802 may include a single layer or a plurality of layers (as shown in FIG. 26) and at least a portion of drive bar 802 may be made of plastic. Still further, the closure apparatus 800 may include a cutting surface 808 (FIG. 27) therein for cutting tissue.

ES 2 396 594 T3

With continued reference to Figures 26 and 27, the plastic cap 804 may include a reinforced section 810 that may increase the strength of the closed cap 80 or may provide a stronger connection between the cap. 804 and the horizontal portion 8 06 of the closure apparatus 800. It is also envisioned that cap 804 can be removably attached to closure apparatus 800. In such an embodiment, the cap 804 can be removed and replaced if any substantial wear or damage occurs.

Figures 27a-27d illustrate the closure member of the present invention shown generally as 800 '. As discussed above with respect to closure element 800, closure element 800 'may include an I-shaped cross section including an upper lip portion 802', a lower lip portion 804 ', and a lower lip portion 806'. vertical bar extending between the upper flange portion 802 'and a lower flange portion 804'. The closure element 800 'can be formed of metal, for example, stainless steel, etc. Each of the upper rim portion 802 'and lower rim portion 804' includes an outer surface 807 'and an inner surface 808'. Each internal surface 808 'includes a cutout or recess 810' (FIG. 27d) that is dimensioned to receive an insert 812 'formed of a material having a low coefficient of friction. In one embodiment, insert 812 'is formed of plastic although it is envisioned that other materials having a low coefficient of friction and required strength characteristics may also be used to form insert 812'. As illustrated, insert 812 'may extend slightly below inner surface 808' of upper flange portion 802 'and slightly above inner surface 808' of lower flange portion 8 04 ' . Although the inserts 812 'are illustrated to extend along only a portion of the length of the inner surfaces 808' of the upper and lower flange portions 802 'and 804', it is envisaged that the pieces 812 The insert 'may extend the entire or substantially the entire length of the inner surfaces 808'.

The vertical bar portion 806 'includes a cutout 814' sized to receive a drive bar (see, for example, drive bar 802 in FIG. 27) and a knife blade 816 '. Knife blade 816 'may be attached to vertical bar portion 806', such as by welding, or directly machined therein. Similarly, the drive bar may be welded to, integrally formed with, closure member 800 ', or secured to closure member 800' using other known attachment techniques.

Referring to Figures 27a and 27c, the distal edge 819 'of the lower rim portion 804' includes a rounded chamfer or edge 820 '. Distal edge 819 'is the edge that first engages tool assembly 17. In one embodiment, the rounded edge 820 'is spaced from the insert 812' and is positioned to effect the approach of the pivoting jaw of the stapling device. See figure 1.

Referring to Figures 27c and 27d, in one embodiment insert 812 '(Figure 27a) is attached to upper flange portion 802' and lower flange portion 804 'to form insert 812' in place. . This can be done using an injection molding process. In one embodiment of the process, a hole 822 'is made in and through the upper and / or lower flange portions 802' and 804 'to communicate with the recesses 810' of the upper flange portion 802 'and the portion 804'. bottom flange. Each hole 822 'communicates from the outer surface 806' with both recesses 810 'in the inner surface 808' of the upper or lower rim portions. Alternatively, two holes may be made through each of the upper and lower rim portions 802 'and 804', each hole communicating with a recess in one side of the vertical bar portion 8 06 '. Next, closure element 800 'is positioned within a mold and mold material is injected through hole 822' into recesses 810 'to form inserts 812'. The mold can be configured to provide any desired insert configuration. After the molding step, the insert or insert pieces 812 'may be further machined or shaped and the closure element 800' can be machined or cleaned in a known manner to prepare the closure element 800 'for use. in a surgical device.

In one embodiment of the present disclosure illustrated in Figures 28 and 29, a tool assembly 850 is illustrated. The tool assembly 850 of this embodiment includes a channel 852, a first attachment member 860, a second attachment member 870, an anvil assembly 880, a first attachment rod 890, and a second attachment rod 892. . The first and second tie rods 890, 892 provide a strong connection that makes it easier for the elements of the tool assembly 850 to stay together.

Channel 852 includes an opening 854 (two openings illustrated) adjacent its proximal end and first attachment member 860 includes a shoulder 862 (two shoulders illustrated) extending therefrom. Channel 852 can be connected to the first link member by locating opening (s) 854 over alternate (s) 862, thus providing a pivotal connection between them. Although not explicitly illustrated in the present embodiment, channel 852 can house a plurality of surgical fasteners or a staple cartridge.

Anvil assembly 880 includes an anvil cover 882 and anvil 886. Anvil 886 is configured for mechanical engagement with anvil cover 882, for example, through a press fit connection. An opening 884 extends at least partially through a portion of the anvil cover 882. Aperture 884 is configured to fit over a protrusion 872 provided in second attachment member 870, thus providing a connection between anvil assembly 880 and second attachment member 870. Additionally, the anvil cover 882 includes at least one opening 888 that extends at least partially therethrough in one embodiment of the disclosure. Aperture 888 is configured to fit over shoulder 862 of the first

ES 2 396 594 T3 connecting element 860. In such an embodiment, the anvil assembly 880 can be pivoted relative to the first link 860 and the second link 870.

The first attachment member 860 includes a first aperture 864 and a second aperture 866 extending therethrough. The second attachment member 870 also includes a first aperture 874 and a second aperture 876 extending therethrough (FIG. 29). In addition, the first link 860 and second link 870 are mechanically engaged, such that the first openings 864, 874 are substantially aligned and the second openings 866, 876 are substantially aligned.

To secure the first link 860 with the second link 870 (and thus the channel 852 and anvil assembly 880), the first link rod 890, or a portion thereof, is inserted through the first openings 864 and 874. To further secure the elements of the tool assembly 850, the second tie rod 892, or a portion thereof, is inserted through the second openings 866 and 876. The first tie rod 890 and / or the second tie rod 892 are intended to be rivets, such as two-part rivets that can be tightened.

In one embodiment of the description, the tool assembly 850 is part of a disposable loading unit, which can be hinged. Articulation of the tool assembly 850 may be facilitated by pivotally attaching the tool assembly 850 to a body portion of a surgical instrument through a protrusion 874 extending from the second attachment member 870 and a connecting piece (such as as connection piece 710 in figure 21). Additionally, a method of assembling the tool assembly 850, as described above, is contemplated by the present disclosure.

It will be understood that various modifications can be made to the embodiments disclosed herein. For example, the locking assembly described above can be incorporated into a variety of surgical instruments that include DLUs and is not limited to the use of linear staplers. In addition, the DLU may be configured to receive an insertion tip of the surgical instrument unlike described. Therefore, the above description should not be construed as limiting, but merely as exemplifications of the various embodiments.